Weichai WP7 Diesel Engine Service Manual (EN)

Operation & Maintenance Manual and User Service Guide WP7 Euro Ⅵ Vehicle Diesel Engine Operation & Maintenance Manual and User Service Guide 610800820289

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Operation & Maintenance Manual and User Service Guide Foreword WP7 Euro Ⅵ vehicle diesel engines are developed based on a new design concept and meet the Euro Ⅵ emission standard. WP7 diesel engines feature compact structure, reliable operation, high economy indexes and power performance, quick startup, easy operation and convenient maintenance and are the ideal power for the middle/heavy-duty trucks and middle/large buses. This manual, as reference, describes methods of operation and maintenance, inspection essentials and service guide for WP7 diesel engines.

To make best use of WP7 diesel engines, users are expected to carefully read and learn the diesel engine structure, maintenance and operation methods. The diesel engine service life can be significantly prolonged if the users can follow this manual during maintenance. With the increasing numbers and improving of the variants of WP7 vehicle diesel engines, users are expected to timely pay attention to the technical information released by Weichai. Any revision will not be notified in advance. For more information about new products, please visit http://en.weichai.com . March. 2014

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Operation & Maintenance Manual and User Service Guide Special instructions 1) It is very dangerous to increase the power by modifying the ECU data. Any change of ECU data without permit will lead to invalid “Three guarantees” and so on, and all losses and the legal responsibilities arising therefore would be borne by the users. 2) Common-rail fuel pump, turbocharger, urea solution injection system and other components, as the precision parts, should not be impacted or dismantled without permission; otherwise the "Three guarantees" will be invalid.

3) Please use Weichai designated fuel strainer and fine filter; otherwise any damage to the common-rail system will not be covered by the “Three guarantees”. 4) For Euro Ⅵ Diesel Engine, in order to make sure the normal operation of the SCR processor, please add urea solution produced by formal manufactures timely. It is forbidden to use urea solution mixed privately or other solutions, otherwise, all losses and the legal responsibilities arising therefrom would be borne by the users. 5) Please go to the formal fuel station to refill the stipulated fuel, otherwise any damage to the fuel system due to fuel quality will not be covered by the “Three guarantees”.

6) For Euro Ⅵ diesel engine, special Euro Ⅵ diesel fuel should be used, otherwise any problems arising therefrom, such as the emissions exceeded the limits of standard, should be borne by the users. 7) Any service such as repair or maintenance should be done at the designated service station and spare parts specified by Weichai Power should be used; otherwise, any damage to the diesel engines should be borne by the users. 8) The product norm follows Q/WCG 100.

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Operation & Maintenance Manual and User Service Guide Notice 1. Before the first use, the engine should go through a 50h trial run. For more information, refer to the running-in requirements. 2. After the cold start, the engine should slowly increase the speed. Don’t let the engine run at idle speed for a long time or suddenly speed up. After running with heavy load, do not immediately stop. It is necessary to idle for 5-10 min at low speed. 3. It is prohibited to work without air filters which could prevent air from entering the cylinder without being filtrated.

The air filter should be regularly maintained or replaced, otherwise power reduction, parts wearing and other problems would happen. 4. Please select specified grades of fuel and oil and use the special and clean containers. The fuel and oil should be filtrated with the strainer before being added. 5. If the diesel engine fails to start within 15s, repeat after at least 2 min. 6. It is prohibited to fill the diesel engine with water rather than antifreeze, which could greatly reduce the engine life and leads to damage of the after-treatment system and other parts. 7. Before the start, please ensure the antifreeze, urea solution and oil are at the proper levels. 8.

The strainer of urea solution tank must be cleaned regularly, otherwise the OBD system will giving alarm. 9. When the vehicle is parked for a long time and the ambient temperature is lower than the freezing point of antifreeze, it is necessary to drain the water out through the discharge valve of the air compressor. 10. It is not allowed to reuse the cylinder head gasket and all kinds of asbestos or metal coated sheet gaskets. 11. Feedback of engine quality information Our company performs the quality-trace filing for WP7 diesel engines, therefore users are expected to fill the card and send it back to our company for further service based on the card.

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